Metal Corner Connector with Grooved Weld Seats for Tube Alignment
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Solution Overview
Problem
Existing metallic corner connectors lack the mechanical stability required to securely connect metallic tubes at various angles, and there is a need for a method to produce devices and rail vehicles that utilize such connectors effectively.
Innovation Solution
A metal corner connector with strategically designed connection areas, including projections and grooves for HV welding, which ensures high mechanical stability by allowing precise alignment and full-circumference welds, and a method involving extruded metal to reduce production costs and enhance load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional connection methods are used for metallic corner connectors, then the structure is simpler to manufacture, but the mechanical stability and load-bearing capacity are insufficient
Solution Approach 1:
The connection area is segmented into multiple functional zones: an outer surface for positioning, projections for structural support, and grooves for welding material accumulation. This segmentation allows each zone to perform its specific function optimally, achieving high mechanical stability through welding while maintaining manufacturability via extrusion processes.
Solution Approach 2:
The outer surface and projections are pre-formed during the extrusion process to provide precise positioning features before welding. The grooves are also formed in advance to guide welding material placement. This preliminary preparation ensures accurate alignment and high mechanical stability without requiring complex post-processing or assembly operations.
2Manufacturing precision
If precise alignment features are added to the connection area, then the angular alignment precision improves, but the device complexity increases
Solution Approach 1:
The positioning function (outer surface), structural support function (projections), and welding guidance function (grooves) are merged into a single integrated connection area design. This unified structure achieves precise angular alignment (≤1°) without requiring separate alignment fixtures or complex assembly procedures, thereby maintaining manufacturing simplicity while achieving high precision.
3Strength
If HV welding is used to achieve high mechanical stability, then the connection strength increases, but the production cost and process complexity increase
Solution Approach 1:
The grooves in the projections automatically accumulate and retain welding material during the HV welding process, eliminating the need for separate welding material application steps. The connection area's geometry itself serves the welding process by guiding material placement and ensuring complete penetration, thereby achieving high connection strength while simplifying the welding process and reducing costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a lightweight, mechanically stable connection capable of supporting significant loads, suitable for rail vehicles and devices, with precise angular alignment and high load-bearing capacity, while simplifying production and reducing costs.
Implementation Method 1
at least one connection region is set up to be mechanically stably connected by welding to a metal tube
Implementation Method 2
An HV weld seam is particularly preferably produced at least partially during the welding
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a metal corner connector (1) comprising at least two connection regions (2) which are arranged on a lateral surface (3) of the metal corner connector (1), wherein at least one connection region (2) is designed to be mechanically stably connected via welding to a metal pipe (4) extending along a main extension plane of the metal corner connector (1). The connection region (2) comprises at least one protrusion (6) with a groove (7), which is designed for receiving a welding material. The connection region (2) has an outer surface (8) which is adjacent to the protrusion (8) and is designed as a contact surface for an end face of the metal pipe (4). The invention also relates to a method for producing a device having a metal corner connector, a device having a metal corner connector and a rail vehicle having a metal corner connector.